The focuses of this course are as follows:

• Risk Based Maintenance to ground maintenance contracts
• Dashboards and real-time performance monitoring and Key Performance Indicators to monitor performance
• Understanding Outsourcing methodologies
• Contracting types, including Service Level Agreements
• Continuous improvement and performance management - how to evaluate the performance with all parties involved

By the end of this course, delegates will be able to:

• Evaluate and justify your maintenance programs using Value = Benefit - Cost
• Apply Life Cycle cost and risk planning to your facility assets
• Target Maintainability and/or Reliability in the development of your facility maintenance plans
• Learn the Plan, Do, Review cycle of continuous improvement
• Understand how to decide rationally what maintenance activities to outsource and what is not
• Understand the different types of maintenance contracts and when and how to apply them
• Learn how to define service levels and monitor the contractor performance
• Learn how to develop and negotiate a maintenance contract
• Recognize the pitfalls
• Understand how to evaluate the delivered performance of all parties involved
• Learn how to implement maintenance contract management

• Maintenance managers
• Reliability engineers
• Mechanical Engineer
• Control engineer
• Operation engineer
• Operation supervisor
• Planning Engineer
• Mechanical Technician
• Safety engineer

The expert will suggest ideas and theories to the delegates and then encourage them to test out the ideas by the use of:
• Discussion
• exercises
• Case studies & DVDs
• group exercisess
• examples

Day1

Reliability Engineering Fundamentals

• Basic Principles of Reliability Analysis
• Definitions and classifications of equipment failures.
• Overview of failure modes and mechanisms.
• Role of the Reliability Engineer

Asset Cost Management Introduction  

• Definitions of reliability, maintenance & asset management
• The total cost of maintenance
• Best practice reliability and maintenance processes
• Auditing performance

Root Cuase and Analysis Process

• Introduction to RCA methodologies and tools.
• Conducting RCA to determine underlying causes of failures.
• Work Identification and Defect Reporting
• Ask 5 Whys to anaylsis faluires and action
• Case study in conducting root cause analysis and FMEA.
• Process FMEA, Design FMEA, Maintenance FMEA.

Day 2

Failure mode and effects analysis (FMEA)

• • • Reliability centered maintenance (RCM)
    • FMEA and FMCA
    • Design FMEA and Process FMEA
    • Physics of failure (POF)
    • Field data analysis
    • Fault tree analysis
    • Eliminating single point of failure (SPOF)
    • Operational hazard analysis
    • Looking at maintenance history to analyze failure rates and collect failure data

Laying the Groundwork  

• Team-work maintenance, operations, stores
• Corporate asset management expectations
• Asset performance expectations
• The forms of asset failure and degradation
• The causes and nature of asset failure and degradation
• The effects, cost and risks of asset degradation

Day 3

Applying the Value Based Process  

• Breaking the cycle of failure and degradation
• Select PM tactics on the basis of costs and risks
• How to determine PM intervals
• Condition based maintenance types and the PF-curve
• The four important reliability functions
• Optimizing spares to support the maintenance program
• Maintenance program cost and risk based justification

Making Reliability Improvement Normal Practice

• Define  reliability objectives
• Develop reliability plan
• Implement reliability plan

• Monitor and measure reliability results

 Day 4

Ensuring the Continuity of the Value-Based Process  

• Failure Reporting, Analysis and Corrective Action System requirements
• How to quantify chronic failures and losses
• Use Pareto analysis and stratification to focus the value-based analysis
• Quantify losses in life cycle terms
• Reliability Analysis Case Study

 Reliability, Maintenance, Asset Management for Failure Prevention

Preventive Maintenance (PM)

• Optimising Preventive Maintenance
• Condition-based Maintenance Intervals

Predictive Maintenance (PdM)

• Overview of predictive maintenance technologies.
• Optimising Predictive Maintenance (Condition Monitoring)
• Repair-Replace decisions

Reliability-Centered Maintenance (RCM)

• Principles of RCM and application in industrial settings.
• Developing RCM plans to enhance equipment reliability.
• Component Failure Data Modelling

Day 5

Supporting Process that Lower Life-Cycle Costs  

• Planning and scheduling best practice
• Cost effective manpower and skills deployment
• Performance indicators to drive continuous improvement

Maintenance Contracts

• Maintenance contract types
• Parties involved
• Choosing the right contractor
• Costing the service
• Defining Key Performance Indicators to monitor the performance
• Common Causes of Equipment Failure

Developing the Maintenance Contract  

• Vendor management
• The contracting cycle
• Assemble a team
• Assess, determine and specify the required service levels

Outsourcing Considerations

• Introduction to program
• Introduction delegates
• The business impact of maintenance
• Activity on asset matrix

CDGA attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.